Project D2 S8 40vQM

[Crispy222]

Yes, M for manual.

Picked up a '01 (MY 2000) D2 S8 off the classified with a blown transmission. My first Audi besides my B5 Passat which is pretty much a B5 A4 FWD underneith. 1 & 2 gear are 90% gone. Did slip it from a stop sign with faulting once. 3 & 4 have a little grip, 5th is fine. It will go into limp mode and lock into 5th gear, which is fine from 20-100+ mph. Perfect car to transplant a 6 speed manual into. Overall the car rides great, just needs some TLC to the interior and a few random bits here and there (radio buttons has been abused, cluster led repair, headlight auto level sensor for the front, front wheel bearings). The suede seat bottoms are pretty beat and need to get recovered at some point, but there are no tears or holes. A/C needs to get checked out, looking like it just needs a re-charge from not being used in so long) 121,286 miles on the OD when I picked it up and no accidents or incidents on the CarFax report.

Got it home from Boston to Syracuse without an issue, ie. without plates, without a temp tag, without insurance, without a title. Brakes are rust from sitting around. Calipers work great and pads are atleast 50%, so just going to turn the rust off the rotors and run them til next year. I think they should last me 10-15k miles yet. Whom ever put the wheels on last was an idiot and over torqued them (probably a 1/2" impact til yield). So a 24" breaker bar and 4 foot jack handle to remove all 20 lug bolts. Calipers came off without an issue. Got the rotors to the machine shop to get cleaned up. Probably blast some of the rust off the inner hats and vains as it was pretty crusty there too. Also found that the right rear caliper is missing the e-brake bracket and spring, so I'm searching for that rigth now. Pretty important.

In the mean time, doing a lot of reading on what has been done before. Looking at 01E or 02A swap and what would need to be custom or modified. I'll post some photos later. Any info and links would be greatly appreciated.

If you want to see what I've done to the Passat, click on the 2L Build in my signature.

[Scotty@Advanced]

02A is a FWD 5 speed. You probably mean an 0A2 but that is FWD only. The 0A3 is AWD. It is also going to be difficult to retrofit into the S8 as it uses an entirely different mounting system. It also has no speedometer pickup on the diff, 01E is probably your best bet, but keep in mind all the S8/A8 manual supporting parts will be European only.

[Crispy222]

I don't know the transmission codes and probably got them confused. 02x possibly? Anyways B6 S4 trans not possible? What is its final drive ratio? same as B5 S4/C5 A6 2.7t rear end? Sounds like that is the diff that bolts in.

As far as supporting parts, Front axles - I read UrS6 possible or Raxle. Drive shaft - DSS Aluminum ($900-1000), guessing I'm going to have to stay with 2 piece, but I bet they could supply a better support bearing then OEM. Shift Linkage - length S4 set or import from Europe. There are a couple of guys doing Euro S8 manual flashes. Looking to delete SAI, 2nd O2. ($350-500).

[coolgraymemo]

Pics?

[Crispy222]

Pics?

Coming

I found the 01x FWD and 02x AWD, both 6 speeds, were in B6 A4 1.8 and 3.0L. I'm weary of the durability when handling 400 ft-lbs. Looks like 01E or 0A3 are the choices.

[Scotty@Advanced]

I don't know the transmission codes and probably got them confused. 02x possibly? Anyways B6 S4 trans not possible? What is its final drive ratio? same as B5 S4/C5 A6 2.7t rear end? Sounds like that is the diff that bolts in.

As far as supporting parts, Front axles - I read UrS6 possible or Raxle. Drive shaft - DSS Aluminum ($900-1000), guessing I'm going to have to stay with 2 piece, but I bet they could supply a better support bearing then OEM. Shift Linkage - length S4 set or import from Europe. There are a couple of guys doing Euro S8 manual flashes. Looking to delete SAI, 2nd O2. ($350-500).

I used a Euro S8 flash for the car I did. As far as axles, Ur axles are wrong lengths.

[Crispy222]

I used a Euro S8 flash for the car I did. As far as axles, Ur axles are wrong lengths.

TozoM8 posted that he used:

URS6 front axles, 01E trans with spacer, Clutch/flywheel of your choice (at least stage 3) driveshaft needs to be extended by 4.5". B5 S4 shifter linkage needs to be extended by 3.5"

and kept the S8 rear diff as it is 4.111 ratio
http://forums.quattroworld.com/a8/msgs/12898.phtml

I've watched the progess on the B5 A4 guys doing the 4.2 swaps (A8 and S6 motors). Looks like they are preferring to not use the trans spacer and go with a v6 30v flywheel due to it being shorter setup which keeps the engine as far back as possible. I'm wondering how this would work in the S8, as I'm planning on going with a new flywheel and clutch setup (probably CM FX400). For front axle, I'm thinking about taking the current axles and whatever axle that go with the transmission I got, cut them to length and have them welded and balanced at a local driveshaft shop. I'll set it up with the proper length for a lowered car also as coilovers will be involved.

[Crispy222]

Here's a photo album I found that will be handy. Made his pedals from a UrS6 set.
https://plus.google.com/photos/10413...001?banner=pwa

[Crispy222]

As far as axles, Ur axles are wrong lengths.

Looks like the RF will fit the LF and then RF will need a RF extended 1" or maybe just extended the LF to fit the RF.

[Crispy222]

Photos for those who are watching.



I little rough on the outside.

Removed that sticker before I drove it home.

Interior has been abused. No other way to put it.


Thinking about sourcing a manual cluster, so I probably won't get the pixels fixed in this one.

[Nollywood]

Hi there,

The B6 S4 tranny will physically bolt up to the S8 motor. But you'll have issues with shifters, as well as speedo output. The B6 S6 doesn't have a speedo sender in the trans, the speedo gets pulses from the ABS wheel speed sensors, via the ABS control unit. Lots of coding involved, even if fitting the B6 S4 tranny to a pre-2004 B6 1.8T Quattro.

I would stick with the 01E, which is also a stronger unit.

If you need genuine S8 01E axles, I have a pair, which I purchased from Germany about a year ago, but never used as I sold my S8 to a buddy.

[AudiA4_20T]

this is awesome

[Crispy222]

Working on this is cutting into car time


But I am in process of ordering parts. The list is growing.

[Crispy222]

Swapped in a different steering wheel. B7 S4 DTM suede wrapped wheel. Matches perfectly with my dark grey interior.

Old


New


Thanks A4Rob

[Crispy222]

In between working on prepping the driveway for concrete I found some time to finish copper air lines in the garage and work on the car. Three drops and a 50' 1/2" hose reel will put the rust busting impact back in action.

Parts acquired: UrS6 front axles, hydro pedal assembly, clutch master, USPM metal slave, braided SS clutch and rear brake lines, 034 upper adjustable & lower density line CA kit, upper density strut mounts, front sway bar links.

Awaiting: JHM 01E rebuild kit with new shift collar and carbon syncros, JHM trio shifter, JHM delrin shift knob, TDI 6th gear .55 ratio.

Dropped the stock exhaust and unbolted the downpipes from the manifolds. Removed the 2nd air pump, valves, & cross tube. Unhooked the wiring from the top of the motor. Ready to pull valve covers and intake manifold. IM flappers are not hooked up. They move freely but the linkage and arms are busted. Looking at the shiny billet parts from gruven for replacement. Looks like I'll need one vacuum actuator as the ball end is broke off/missing. Will be doing new silicone vacuum line too.

Need to figure out the difference between the stock coil wiring and 2.0fsi wiring so I make the pin change and run the coils. I have four spacer plates, need to get four more on my next order from 034.

[EuroxS4]

I am wondering about this swap as I also picked up a 2000 a8l with a blown trans.I think 01E is theway to go,as far as the swap goes.I have read 2.7 flywheels and 2.8 flywheels will work with the 40v motor.Anyone know which flywheel bolts to use??There are different lengths.Clutch I would assume would be a s4 or a b5 rs4 unit if using a 01E transmission??Or possibly stage 2 or 3 from southbend if someone wants to use the k03 or k04 turbos on the a8l with some custom made adapters and plumbing??

As far as the starter goes I would assume to use the stock v8 starter??

Slave cylinder for a 01E I would assume as well as the line.With the issue being the pedal cluster and brake fluid resovoir?? and the clutch master cylinder?

Either shorter or extend the drive shaft,depending on which rear diff your using either b5 s4 or european d2 s8 manual diff has a final ratio or 4.11 as well.I would assume d2 s8 rear axles would bolt right in as would the rear diff.

Extend the b5 s4 shifter linkage,disconnect the TCM and recode ECU for a manual transmission.Hook up the clutch switch and that should be it.

URS6 front axles might fit or need to be extended.


Oh and swap in a tdi 6th gear .56 ratio for great fuel economy?

[Crispy222]

The flywheel bolt length will be determined by the flywheel thickness. So if you're using 2.7t flywheel, use 2.7t flywheel bolts. I'm using an CM FX400. RS4 clutch would be a minimum requirement IMO. K03 would be pointless, far to small. RS6 K04/K24/Tial GT28xx. Anything would need a ton of fabricating assuming you're not pulling the complete motor from a RS6.
'
I plan on using the 40v starter. USPM 01E metal slave.

Brake fluid res already has the nipple for the clutch master line, just need to cut the crimped section off. Pedals get tricky. I found where one guy used UrS6 pedals on to his D2 pedal assembly with minor fab work. I'll have to fab a plate for the UrS6 clutch master cylinder to mount to. The D2 assembly already has provisions for a clutch switch.

The prop shaft will need to be extended as the 01E is shorter than the auto. I plan to use the stock rear diff as every swap I've read has. Shift linkage needs to be extended, recode ECU for manual and eventually pull the harness/TCU and clean it out. Using UrS6 axles flipped right to left. One front axle will need to be extended. I have the axle out of the car, but havn't put them side by side yet to see if I can use the inner half of a UrS6 to bolt to trans and outer half of D2 S8 to bolt to the hub.

TDI 6th gear .56 for cruising 80mph at less than 2500rpm. Hopefully push 26-28mpg on the highway.

[Scotty@Advanced]

Your not going to see 26-28 mpg on the highway.. Probably more like 22-25.

The B5 A4 and S4 use the same flywheel bolts so it doesn't matter if your going to use stock flywheels. The B5 2.8 A4 flywheel and clutch don't require you to use the spacer which is a plus.

When you need to overhaul the transmission I offer the best price on trans overhaul sets. I can also order the tdi 6th gear as well as offer turn key transmissions.

I also offer a plug and play harness to take care of the underhood re-wiring...

AAM 01E trans overhaul sets
AAM 01E quattro transmissions
AAM Tiptronic to 6MT harness
AAM 01E TDI 6th gearset

[Crispy222]

Your not going to see 26-28 mpg on the highway.. Probably more like 22-25.

I didn't calculate it, but I got 24-25 mpg at 75-80mph on the drive home after picking it up. Hopefully I'll see a 1-2 mpg better with the TDI gear.

[EuroxS4]

I think a a8 in this body with a whole b5 s4 drivtrain 6 speed of course stage 3++ with some nice numbers would be a nice car to drive.Plus more room under the hood out front I would assume.Possibly for bigger turbos??LOL.

[TerminA8r]

I'm pretty sure that you can see 28-29 mpg on the freeway cruising at 80 mph with the TDI .56 6th gear.

http://forums.quattroworld.com/a8/msgs/85391.phtml

Quote from ad:
"The transmission is rock solid, built by Gabor himself with the euro TDI .56 6th gear.
~18MPG in town, but ~29MPG on the highway cruising at 80. On a full tank you can get ~600 miles"

[geojt72]

I own a 01 s8. I would love to do the six speed swap. any rough input in the cost, all said and done?

[Scotty@Advanced]

I own a 01 s8. I would love to do the six speed swap. any rough input in the cost, all said and done?

Euro only parts are pretty expensive as it the custom driveshaft needed. I'd guess about ~5-6K labor included

[Crispy222]

I'll be getting more work on this soon. Moved into some shop space with a few fellow VAG owners. Vanagons getting AEB and one getting a MK3 TDI swap, Corrado VR getting charger and air to liquid cooler. Another Corrado getting an AEB swap.

Picked up an '01 A6 2.7t 6-speed. Decided it was way to nice condition to part out. Fixed a few things so far, like the cluster LED, passenger mirror glass, rear-view mirror. Its missing some exhaust clamps so I picked up some cat-less pipes. Just getting that finished up. New coilovers, H&R rear sway, JHM shifter, and swaping over some parts from my B5: adjustable upper control arms, front sway bar end links, Big Red front brakes. It will make a great daily for the time being.

Picked up another S4 transmission and rear diff from a part out. I need to tear that down and rebuild it with the JHM 1-2 collar kit, sycros and TDI 6th. As soon as the lift gets installed into the shop, I'll get the auto trans, pedals, shifter, wiring out of the S8. Then its all fab work. Making the prop shaft and axles work will be a pretty good task on their own. Modify pedals, some wiring and clutch lines. It should more along as long as I'm not traveling for work.

[geojt72]

5-6k is not that bad. my tranny is fine for now. just turned 150k. and runs fine, but you always think when is it gonna start acting up you know! I have already looked into rebuilds at about +or- 5000$. guess I'm just wondering the actual reality of a complete conversion.

[woofster]

Subscribed to this thread! Looking forward to seeing the progress.

[A4Rob]

Steering wheel looks great!

[Crispy222]

I have the next S4 trans on an engine stand I got for $5. Then had to re-make two of the tubes and had them painted at work. Tearing that down as soon as I'm finished with the siding I've been redoing on my house. My friend is getting his lift installed soon at our shop so just have to get my Passat trailer home and the S8 trailered there some weekend. I have 90% of the parts. Just need to get a hold of the time.

Also no H2Oi for me this year. I have a bachelor party in Vegas that weekend. So time line looks like fall to get it on the road and sorted before any snow so I can sell the A6 2.7t I've been driving. Should make an easy sell with a set of snow tires

[Dan McBoost]

Wait. You are in cuse? How do we not know each other.

[Crispy222]

Because I'm gone as much as I'm in Syracuse.

I'm in the shop with Forbes and Carter in Liverpool. The car should be down there in a weeks. For now, it's in my driveway's third stall.

[Crispy222]

Another 6 weeks few by. So much travel. So little time for cars. Well this holiday weekend I got the S8 moved to my shop. I got the proper shaft out and every transmission bolt out but one in my driveway. I'm just going to drop the motor and trans on the subframe with a cherry picker and then separate. It will be easier to do the finish disassembly, new timing components, and oil cooler pipe.

Today I received my long tube headers. I'll need to add some exhaust manifold gaskets and hardware to my next parts order.

[zokissima]

Subscribed!! Insane project. Couldn't be more inspired.

What do you do for a living that requires so much travel?

[Crispy222]

I work as a service technician for automated equipment. But soon to be off the road permanently and into a controls engineering position. Way less travel is good for more work done and more parts made. Building a wiring table next.

[icrashcars]

Please tell us about those headers!! Custom made or is someone selling them?

[Crispy222]

Please tell us about those headers!! Custom made or is someone selling them?

Someone is selling them. XSPower made, but they look to be decent construction. PM me if you're looking for a set. I don't want to advertise for business that is not a paid advertiser.

[Crispy222]

Got to work on the car Sunday afternoon/evening. I helped out my friend solve some boost problems in his S/C 12v VR Corrado. All new AWI, piping, and short running. Ever coupler leaked, pin holes in the welds, welded beads that were 1/2" off the end of the tubes, TB to adapter, adapter to intake plenum. Just bad news. And the timing might be a tooth off.

But on the second night, the engine and trans has been removed. I feel like I was wrestling a baby whale on the cherry picker.


Got the passenger side engine bracket off to expose the lower starter bolt that was not accessible in the car. It gave way like the rest of the bolts, and I split the two. Drug the trans into the corner til I find someone that wants the core. 5H-24A

[Crispy222]

Remove the other mount bracket, drained the coolant from the block, and got the TQ converter and flex plate off. Removed the flex plate spacer and cleaned off the backside of the motor. Fairly clean. A little white sealant squeezed out between the block and upper oil pan. I wonder if they had been separated or just from the factory like this. Rear main doesn't appear to be leaking, no oil, just dusty/salt remnants. Spray it down with some brake clean and blew off all the crude. Remove both the exhaust manifolds. Two nuts stripped and had to use a 3/8" turbo socket. 5 studs came out in the process. I saved 4 of them and reinstalled them into the head. One snapped in the exhaust manifold tube nut, but I had a spare around from a 20v head.

Test fitted a core 01E with spacer plate. Then lined up one exhaust manifold. Had to remove the oil pressure sensor and coolant tube from the oil housing. They both need to be removed in the future anyways. Not sure how the coolant tube from the oil housing to the rear crossover tube is going to fit around the headers. Its going to be very tight if not dimpling the header tube for cyl 1 and pulling some thermal barrier on it.






Not decided if I want to cut the 2.5" v-bands off and go up to 3" with dual 3" to the rear. Or go a little cheaper with the 2.5" existing on the downpipes and 2.5" to the back?

[lunamarA4]

what happend to this car

always wanted to know more about those headers and if there were any drawbacks to them